Window seal assembly for limiting air leaks from a vehicle frame into a passenger cabin of a vehicle

ABSTRACT

A vehicle door sealing assembly includes a door trim panel and an inner frame panel defining a door cavity, a window positioned proximate the door trim panel and the inner frame panel, a beltline seal disposed between the door trim and inner frame panels and in selective engagement with the window and a leak seal extending between the door trim panel and the beltline seal to divert a flow of air from the door cavity.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent applicationSer. No. 15/070,135 filed Mar. 15, 2016, entitled WINDOW SEAL ASSEMBLYFOR LIMITING AIR LEAKS FROM A VEHICLE FRAME INTO A PASSENGER CABIN OF AVEHICLE, the entire disclosure of which is hereby incorporated herein byreference.

FIELD OF THE INVENTION

The present invention generally relates to a window seal system, morespecifically, a window seal system that limits air leaks from enteringthe passenger cabin from areas around the vehicle frame.

BACKGROUND OF THE INVENTION

The vehicle frame includes multiple components that define variousframed cavities within which components of the vehicle are located. Manyof these cavities of the vehicle frame are interconnected, such that airflow from one space can move to another. Such spaces of the vehicleframe can also be located within vehicle doors and near operablewindows.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a vehicle door sealingassembly includes a door trim panel and an inner frame panel defining adoor cavity. A window is positioned proximate the door trim panel andthe inner frame panel. A beltline seal is disposed between the door trimand inner frame panels and is in selective engagement with the window. Aleak seal extends between the door trim panel and the beltline seal todivert a flow of air from the door cavity.

According to another aspect of the present invention, a vehicle sealingassembly includes a vehicle frame defining a frame cavity, a vehicledoor having a door trim panel and an inner frame panel that define adoor cavity in communication with the frame cavity. An operable windowis disposed proximate the door cavity and is operable between open andclosed positions. A beltline seal is disposed between the door trim andinner frame panels and is in engagement with the operable window in theclosed position. A first air leak stopper is disposed proximate aboundary defined between the door trim panel and the inner frame panelto divert a flow of air from within the door cavity.

According to another aspect of the present invention, a vehicle doorsealing assembly includes a beltline seal positioned between a door trimpanel and an inner frame panel that define a door cavity of a vehicledoor. A window is disposed proximate the beltline seal and a leak sealextends between the door trim panel and the beltline seal to divert aflow of air from the door cavity when the beltline seal defines adeformed state.

These and other aspects, objects, and features of the present inventionwill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a side perspective view of a vehicle incorporating an aspectof a vehicle frame air leak stopper;

FIG. 2 is a side perspective view of a vehicle frame of the vehicle ofFIG. 1 with the outer body panels removed;

FIG. 3 is a cross-sectional view of a vehicle door of FIG. 1 taken alongline

FIG. 4 is an enlarged cross-sectional view of the vehicle door of FIG. 3taken at area IV;

FIG. 5 is a cross-sectional view of the vehicle door of FIG. 4illustrating a downward force applied to an interior trim panel of thevehicle door;

FIG. 6 is an enlarged cross-sectional view of the vehicle door of FIG. 4taken at area VI;

FIG. 7 is a cross-sectional view of an aspect of a door frame air leakstopper; and

FIG. 8 is a cross-sectional view of another aspect of a vehicle frameair leak stopper incorporated within a vehicle door.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the invention as oriented in FIG. 1. However, itis to be understood that the invention may assume various alternativeorientations, except where expressly specified to the contrary. It isalso to be understood that the specific devices and processesillustrated in the attached drawings, and described in the followingspecification are simply exemplary embodiments of the inventive conceptsdefined in the appended claims. Hence, specific dimensions and otherphysical characteristics relating to the embodiments disclosed hereinare not to be considered as limiting, unless the claims expressly stateotherwise.

As shown in FIGS. 1-6, reference numeral 10 generally refers to asealing assembly for a vehicular door 12 that is positioned between aframe 14 of the vehicle 16 and a passenger cabin 18 of the vehicle 16.The sealing assembly 10 for the vehicle door 12 can include a door trimpanel 20 and an inner frame panel 22 that define a door cavity 24. It iscontemplated that the inner frame panel 22 can be a structural portionof the frame 14 of the vehicle 16 disposed within the door 12 of thevehicle 16. A window 26 is positioned proximate the door trim panel 20and the inner frame panel 22. The window 26 can be vertically operablebetween open and closed positions 28, 30. A beltline seal 32 is disposedbetween the door trim and inner frame panels 20, 22 and is in selectiveengagement with the window 26. The leak seal 34 extends between the doortrim panel 20 and the beltline seal 32 to divert a flow of air 36 fromthe door cavity 24 to substantially prevent the flow of air 36 from thedoor cavity 24 into the passenger cabin 18 of a vehicle 16.

Referring again to FIGS. 1-6, the leak seal 34 of the sealing assembly10 can include a first stopper 50 that is disposed at an edge 52 of thedoor trim panel 20. In such an embodiment, the first stopper 50 canengage the door trim panel 20 at an edge surface 54, where the edgesurface 54 substantially defines a thickness of the door trim panel 20.It is also contemplated that the leak seal 34 can include a secondstopper 56 that is disposed distal from the edge 52 of the door trimpanel 20. As exemplified in FIGS. 1-6, the first stopper 50 can extendsubstantially horizontally from the portion of the beltline seal 32 toengage the edge surface 54 of the door trim panel 20. The second stopper56 can be disposed in a generally vertical direction from the beltlineseal 32 to engage a substantially horizontal and an inward-facingsurface 58 of the door trim panel 20. It should be understood that theleak seal 34 of the sealing assembly 10 can include both the first andsecond stoppers 50, 56, or can include only one of the first and secondstoppers 50, 56, as generally exemplified in FIGS. 3-8.

Referring again to FIGS. 1-6, the door cavity 24 defines a space that isin communication with a frame cavity 70 of the frame 14 of the vehicle16. The frame cavity 70 can include various portions distal from thedoor 12 such as areas proximate the trunk 72, quarter panels 74, roof76, floor 78, and other areas of the frame 14 of the vehicle 16. A flowof air 36 can extend from one portion of the frame cavity 70 to anotherportion of the frame cavity 70 including, but not limited to, the doorcavity 24 defined between the door trim panel 20 and the inner framepanel 22. This flow of air 36 can carry various odors from portions ofthe vehicle 16 through the frame cavity 70 and into the door cavity 24.Such odors can originate from a spare tire proximate the trunk 72,mechanical portions of the vehicle 16, various seals, and othernon-exhaust type odors that, while not necessarily hazardous to theuser, may be unpleasant and detract from the driving experience of theuser.

Various studies have shown that while a user operates the vehicle 16, auser may place their arm upon a top portion 90 of the inner door trimpanel 20 proximate the beltline seal 32 and the window 26. Placing theuser's arm upon this portion of the door 12 of the vehicle 16 exerts adownward force 92 upon a top surface 94 of the door trim panel 20. Thisdownward force 92 of the user's arm upon the door trim panel 20 can actto at least partially separate a portion of the door trim panel 20 fromthe beltline seal 32 and allow for this flow of air 36 to enter thepassenger cabin 18 of the vehicle 16 and carry various unpleasant orotherwise unwanted odors into the passenger cabin 18. The inclusion ofthe sealing assembly 10 of the vehicle door 12 that includes the leakseal 34 made up of at least one of the first and second stoppers 50, 56serves to prevent this leakage of air from the door cavity 24 and intothe passenger cabin 18 when a downward force 92 is exerted in the doortrim panel 20.

Referring now to FIGS. 3-6, when the downward force 92 is applied to atop surface 94 of the inner door trim panel 20 of the door 12 of thevehicle 16, the movement of the trim panel 20, as a result of thisdownward force 92, is generally downward. The first and second stoppers50, 56 of the leak seal 34 are positioned in engagement with the trimpanel 20, such that as the trim panel 20 moves, the engagement betweenthe first and second stoppers 50, 56 and the trim panel 20 ismaintained. In this manner, an air seal 100 is maintained between thedoor cavity 24 and the passenger cabin 18 of the vehicle 16.

Referring again to FIGS. 3-6, it is contemplated that the first stopper50 that engages the trim panel 20 at an edge surface 54 of the trimpanel 20 can resiliently deflect in a bending or twisting-type motion tomaintain engagement between the first stopper 50 and trim panel 20. Theposition of the second stopper 56 is configured to receive the downwardmovement 102 of the trim panel 20 such that the second stopper 56 isresiliently compressed downward in a biasing fashion to maintainengagement between the first and second stoppers 50, 56 and theinward-facing surface 58 of the trim panel 20. In order to allow for asubstantially continual engagement between the first and/or secondstoppers 50, 56 and the trim panel 20, the first and second stoppers 50,56 of the leak seal 34 can be made of a thermoplastic compoundedmaterial that is substantially resilient and elastic in configuration.It is contemplated that the first and second stoppers 50, 56 can beseparate members that are adhered to portions of the beltline seal 32.It is also contemplated that at least a portion of the first and secondstoppers 50, 56 can be formed as part of the beltline seal 32. A foamseal 110 can then be added around the first and second stoppers 50, 56,where desired. In this manner, when a downward force 92 is placed uponthe trim panel 20, the first and second stoppers 50, 56 can be biasedeither in a bending or compressive manner to maintain the seal betweenthe door cavity 24 and the passenger cabin 18 of the vehicle 16. Whenthe downward force 92 is removed, such as when the user removes an armfrom the top surface 94 of the trim panel 20, the resilient and elasticnature of the first and second stoppers 50, 56 returns the first andsecond stoppers 50, 56 to their original state to maintain theengagement between the first and second stoppers 50, 56 with therespective portions of the trim panel 20. It is also contemplated thatfirst and second stoppers 50, 56 can include a foam seal 110 thatextends around an inner thermo-plastic or thermoset material that formsa compounded core 112 that further serves to maintain the seal betweenthe first and second stoppers 50, 56 and the trim panel 20 of the door12 of the vehicle 16.

Referring again to FIGS. 3-6, it is contemplated that the elastic natureof the first and second seals can result in gaps in the seal between thefirst and second stoppers 50, 56 and the trim panel 20, where pressurewithin the door cavity 24 exceeds a threshold pressure 120 within thedoor cavity 24. By way of example, and not limitation, the sealingstrength defined by the lock seal 34, a threshold pressure 120 that canbe within a range of from approximately one pound per square inch toapproximately three pounds per square inch, such that when the internalpressure of the door cavity 24 exceeds this threshold pressure 120,and/or the sealing strength of the leak seal 34, one or both of thefirst and second stoppers 50, 56 may partially separate from a portionof the trim panel 20 to allow excess pressure to escape from the doorcavity 24.

According to the various embodiments, as exemplified in FIGS. 3-6, wherethe internal pressure of the door cavity 24 exceeds the thresholdpressure 120, it is contemplated that various venting mechanismsdisposed between the first and second stoppers 50, 56 can be implementedto allow excess pressure from a door cavity 24 to escape into areasother than the passenger compartment of a vehicle 16. In such anembodiment, where the internal pressure of the door cavity 24 exceedsthe threshold pressure 120, the second stopper 56 may at least partiallyseparate from the trim panel 20 to release this excess pressure from thedoor cavity 24. A venting mechanism disposed between the first andsecond stoppers 50, 56 can allow at least a portion of this excess airflow to be vented to an area distal from the passenger cabin 18. In sucha system, the first stopper 50 can substantially maintain a seal betweenthe first stopper 50 and the edge surface 54 of the trim panel 20. It iscontemplated that certain situations can result in a greatly excessiveinternal pressure within the door cavity 24, such as during a collisionor impact condition where both the first and second stoppers 50, 56 maybe separated from a portion of the trim panel 20.

In addition to maintaining a seal between the beltline seal 32 and thetrim panel 20, the use of the leak seal 34 that extends between the doortrim panel 20 and the beltline seal 32 can also serve to minimizevarious dimensional tolerances in areas proximate the operable window26. It is contemplated that inclusion of at least one of the first andsecond stoppers 50, 56 can allow for a minimal tolerance distance 130between the interior surface 132 of the window 26 and the outermostportion 134 of the trim panel 20. Such tolerance distance 130 can bealong the order of approximately 5 millimeters. This tolerance distance130 can be at least partially attributed to the inclusion of the firstand second stoppers 50, 56 that divert the flow of air 36 from withinthe door cavity 24. The beltline seal 32, in turn, can be decreased insize due to the supplemental sealing engagement between the first and/orsecond stoppers 50, 56 and the trim panel 20. The beltline seal 32,which can include primary and secondary seals 140, 142 that extendbetween the inner frame panel 22 and the window 26 can be decreased insize. The tolerance distance 130 between the window 26 and the innerframe panel 22 can, in turn, also be diminished.

Referring now to FIGS. 3-8, the sealing assembly 10 for the vehicle door12 can include the beltline seal 32 that is positioned between the doortrim panel 20 and the inner frame panel 22 that cooperate to define thedoor cavity 24 of the door 12 of the vehicle 16. The window 26 can bepositioned proximate the beltline seal 32 and a leak seal 34 extendingbetween the door trim panel 20 and the beltline seal 32 to divert a flowof air 36 from the door cavity 24 when the beltline seal 32 defines adeformed state 150. The deformed state 150 of the beltline seal 32 canbe defined when a user places an arm or another part of a body upon atop surface 94 of the trim panel 20 to exert a downward force 92 ontothe trim panel 20 that can cause a deformation in the trim panel 20 andthe beltline seal 32. As discussed above, the leak seal 34, which caninclude one or both of the first and second stoppers 50, 56 can maintaina sealed engagement between the beltline seal 32 and the trim panel 20to divert a flow of air 36 from the door cavity 24 and prevent this flowof air 36 from entering the passenger cabin 18 of the vehicle 16 whenthe beltline seal 32 is in this deformed state 150.

Referring now to FIGS. 7 and 8, the first and/or second stoppers 50, 56of the leak seal 34 can include a lip-type cross section (exemplified inFIG. 7) where the lip seal 160 is biased toward a portion of the trimpanel 20 and deforms with the movement of the trim panel 20 when thedownward force 92 is exerted upon the top surface 94 of the trim panel20. It is also contemplated that at least one of the first and secondstoppers 50, 56 of the trim seal can include a bulb-type cross section(exemplified in FIG. 8) where the bulb seal 162 includes a tubularmember 164 having a central stopper cavity 166 that extendstherethrough. As the downward force 92 is applied to the trim panel 20,the trim panel 20 deflects downward to define the deformed state 150.The bulb seal 162 compresses and serves to maintain the seal between thefirst and/or second stoppers 50, 56 and the trim panel 20. Both the lipseal 160 and the bulb seal 162 are configured to be elastic and deflectback into an original position when the door trim panel 20 moves back toits original position when the downward force 92 is removed from the topsurface 94 of the trim panel 20.

Referring now to FIGS. 1-8, the sealing assembly 10 for the vehicle 16can include the frame 14 that defines the frame cavity 70. The door 12of the vehicle 16 includes the trim panel 20 and the inner frame panel22 that define the door cavity 24, where the door cavity 24 is incommunication with the frame cavity 70. The operable window 26 isdisposed proximate the door cavity 24 and is operable between the openand closed positions 28, 30. The beltline seal 32 is disposed betweenthe door trim and the inner frame panels 20, 22 and is in engagementwith the operable window 26 at least when the window 26 is in the closedposition 30. A first stopper 50 or air leak stopper is disposedproximate a boundary 180 defined between the door trim panel 20 and theinner frame panel 22, typically at the beltline seal 32. The first airleak stopper diverts the flow of air 36 from within the door cavity 24to prevent this flow of air 36 from reaching the passenger compartmentof the vehicle 16. The second stopper 56 or air leak stopper can alsoextend between the door trim panel 20 and the beltline seal 32 tofurther divert the flow of air 36 from within the door cavity 24 and tofurther prevent this flow of air 36 from reaching the passenger cabin 18of the vehicle 16.

According to the various embodiments, the sealing assembly 10 describedherein can be disposed proximate various operable windows 26 or openingsof the vehicle 16. Such operable windows 26 can include operable windows26 disposed within side doors, moonroofs, sliding windows, vent windowsand other operable portions of a vehicle 16. It is contemplated that thesealing assembly 10 operates when the window 26 is in the open or closedpositions 28, 30, or when the window 26 is in a partially open position28. When a window 26 is cracked open, a vacuum can be created within thepassenger cabin 18 that can serve to draw a flow of air 36 from the doorcavity 24 and into the passenger cabin 18. As discussed above, thesealing assembly 10, that can include the first and/or second stoppers50, 56, serves to counteract this vacuum and at least partially limitthis flow of air 36 from exiting the door cavity 24 and entering thepassenger compartment of a vehicle 16.

It is to be understood that variations and modifications can be made onthe aforementioned structure without departing from the concepts of thepresent invention, and further it is to be understood that such conceptsare intended to be covered by the following claims unless these claimsby their language expressly state otherwise.

What is claimed is:
 1. A vehicle sealing assembly comprising: a vehicleframe defining a frame cavity; a vehicle door having a door trim paneland an inner frame panel that define a door cavity in communication withthe frame cavity; an operable window disposed proximate the door cavityand operable between open and closed positions, wherein a portion of thedoor trim panel extends downward in a direction substantially parallelto the inner frame panel and terminates at an edge disposed between theoperable window and the inner frame panel; a beltline seal disposedbetween the door trim panel and the inner frame panel and in engagementwith the operable window in the closed position; and a first air leakstopper disposed proximate a boundary defined between the door trimpanel and the inner frame panel to divert a flow of air from within thedoor cavity, wherein the beltline seal is free of direct engagement withthe door trim panel, and wherein the first air leak stopper extends fromthe beltline seal to the edge of the door trim panel.
 2. The vehiclesealing assembly of claim 1, wherein the first air leak stopper isdisposed within an area immediately between the operable window and theinner frame panel.
 3. The vehicle sealing assembly of claim 1, whereinthe edge of the door trim panel extends below an upper edge of the innerframe panel.
 4. The vehicle sealing assembly of claim 2, furthercomprising: a second air leak stopper extending between the door trimpanel and the beltline seal to further divert the flow of air fromwithin the door cavity, wherein the second air leak stopper is disposeddistal from the edge of the door trim panel.
 5. The vehicle sealingassembly of claim 1, wherein the first air leak stopper includes abulb-shaped cross section.
 6. The vehicle sealing assembly of claim 4,wherein the second air leak stopper includes a lip-shaped cross section.7. The vehicle sealing assembly of claim 1, wherein the first air leakstopper is made of a thermoplastic compound material.
 8. The vehiclesealing assembly of claim 1, wherein the edge of the door trim panel isa surface that is oriented substantially perpendicular to the innerframe panel.
 9. The vehicle sealing assembly of claim 1, wherein thefirst air leak stopper extending between the edge of the door trim paneland the beltline seal diverts the flow of air from the door cavity whenthe first air leak stopper defines a deformed state.
 10. The vehiclesealing assembly of claim 9, wherein the deformed state of the first airleak stopper is defined when a downward force is placed on the door trimpanel proximate the first air leak stopper.
 11. A vehicle door sealingassembly comprising: a beltline seal positioned between a door trimpanel and an inner frame panel that define a door cavity of a vehicledoor; a window disposed proximate the beltline seal, wherein the doortrim panel extends downward to a downward-facing edge that is locatedwithin a space defined directly between the inner frame panel and thewindow; and a leak seal extending between the downward-facing edge ofthe door trim panel and the beltline seal to divert a flow of air fromthe door cavity when the leak seal defines a deformed state.
 12. Thevehicle door sealing assembly of claim 11, wherein the deformed state ofthe leak seal is defined when a downward force is placed on the doortrim panel proximate the leak seal.
 13. The vehicle door sealingassembly of claim 12, wherein the leak seal includes a first stopperthat is disposed to selectively engage the downward-facing edge of thedoor trim panel.
 14. The vehicle door sealing assembly of claim 12,wherein the leak seal includes a second stopper that is disposed distalfrom the downward-facing edge of the door trim panel.
 15. A vehicle doorsealing assembly comprising: a trim panel and an inner frame panel,wherein an edge of the trim panel extends downward to an edge surfacelocated directly between an operable window and the inner frame panel; abeltline seal disposed between the trim panel and the inner frame paneland in selective engagement with the operable window; and a leak sealextending from the beltline seal and directly engaging the edge surface.16. A vehicle door sealing assembly of claim 15, wherein the leak sealextends between the trim panel and the beltline seal to divert a flow ofair from a door cavity when the leak seal is in a deformed state,wherein the door cavity is defined between the trim panel and the innerframe panel.
 17. The vehicle door sealing assembly of claim 16, whereinthe deformed state of the leak seal is defined when a downward force isplaced on the trim panel proximate the leak seal.
 18. The vehicle doorsealing assembly of claim 17, wherein the edge of the trim panel extendsbelow an upper edge of the inner frame panel.
 19. The vehicle doorsealing assembly of claim 18, wherein the edge surface of the trim panelis oriented substantially perpendicular to the inner frame panel. 20.The vehicle door sealing assembly of claim 15, wherein the leak seal ismade of a thermoplastic compound material.